Aerosol delivery device and method utilizing a flavoring reservoir

ABSTRACT

There can be provided a device configured to impart flavouring to an airstream admitted the device prior to the airstream reaching an aerosol generator of the device, the device thereby operable to deliver a flavoured aerosol from an outlet.

RELATED APPLICATION

This application is a continuation application of Ser. No. 18/296,544filed Apr. 6, 2023 which is a continuation application of Ser. No.18/175,933 filed Feb. 28, 2023 which is a continuation application ofSer. No. 17/452,435 filed Oct. 27, 2021, which is a continuation ofapplication Ser. No. 17/443,170 filed Jul. 21, 2021, which is acontinuation of application Ser. No. 16/842,153 filed Apr. 7, 2020,which is a continuation of application Ser. No. 16/377,331 filed Apr. 8,2019, which is a continuation of application Ser. No. 15/503,456 filedFeb. 13, 2017, which in turn is a National Phase entry of PCTApplication No. PCT/GB2015/052212, filed Jul. 31, 2015, which claimspriority from GB Patent Application No. 1414331.7, filed Aug. 13, 2014,all of which as hereby fully incorporated herein by reference.

FIELD AND BACKGROUND

The present disclosure relates to an aerosol delivery device and methodand in particular but not exclusively to an aerosol delivery device andmethod that utilise a flavouring reservoir.

An aerosol delivery device can be used for generating anicotine-containing condensation aerosol.

One example of an inhaler is described in US20110226236 which relates toan inhaler component for producing a nicotine-containing steam/airmixture or/and condensation aerosol by evaporation of a nicotinesolution which is highly diluted with ethanol or/and water. The inhalercomponent comprises the following elements: a housing; a chamberarranged in the housing; an air inlet opening for the supply of air fromthe surroundings to the chamber; an evaporator for evaporating a portionof the highly diluted nicotine solution, the evaporator comprising anevaporation or steam emission surface arranged in the chamber, fromwhich surface the steam produced passes over to the chamber and mixes inthe chamber with the air supplied through the air inlet opening, therebyeventually producing the nicotine-containing steam/air mixture or/andcondensation aerosol. In order to remove the high solvent diluent in theformed steam/air mixture or condensation aerosol to a maximum possibleextent, the inhaler component comprises a two-step solvent removaldevice which consists of a condensate drainage and storage devicecommunicating with the chamber and of a condenser through which theproduced steam/air mixture or/and condensation aerosol can flow.

Another example of an inhaler component is described in WO2011/109848which relates to an inhaler component having: a housing with a housingjacket; a mouthpiece with a mouthpiece opening for delivering aninhalable medium into the oral cavity of a user; a scent reservoir thatis able to communicate with the environment by diffusion and contains ascent, for releasing the scent into the environment and for theolfactory perception of the scent by the user, wherein a) the housingcomprises a housing component; b) the mouthpiece is detachably connectedto the housing component; c) the housing jacket comprises a first jacketpart and a second jacket part; d) the housing component forms the firstjacket part; e) the mouthpiece forms the second jacket part, and f) thescent reservoir is structurally combined with the mouthpiece, has aplanar configuration and is arranged flat on the second jacket part oritself forms the second jacket part.

A non-heating type tobacco flavor inhaler is described in WO2010/095659.According to this document, a non-heating type tobacco flavor inhaler isprovided with an inhalation holder having an inhalation route definedtherein, and also with a filled body disposed in the inhalation route.The filled body consists of tobacco grains, and the inhalation route andthe filled body provide air flow resistance in the range from about 40to about 80 mmAq.

Another non-heating type flavor inhaler is described in WO 2010/095660.According to this document, a non-heating type flavor inhaler providedwith: an inhalation holder; an upstream region and a downstream regionwhich are defined in the inhalation holder, said upstream regionextending from the tip of the inhalation holder up to a partition wall,said downstream region extending, except the upstream region, from thetip of the inhalation holder up to the mouthpiece end and having a frontflow path extending along the upstream region; outside air introducingopenings formed in the peripheral wall of the inhalation holder andallowing the upstream region and the outside to communicate with eachother; and a pouch mounted at the boundary between the upstream regionand the downstream region, extending along the longitudinal axis of theinhalation holder, and releasing the flavor of tobacco.

SUMMARY

Viewed from a first aspect, there can be provided an aerosol deliverydevice comprising: an air inlet; a flavouring reservoir arranged toprovide release of flavouring material to air passing therethrough; andan aerosol chamber arranged to provide an aerosol in air passingtherethrough; and an aerosol outlet; the air inlet, flavouringreservoir, aerosol chamber and aerosol outlet are arranged in fluidcommunication in that order. Thus a flavoured aerosol can be generatedin such manner as to avoid a flavouring reservoir becoming contaminatedwith aerosol particles and/or condensation of liquid from an aerosol,while at the same time providing that the whole air volume of theflavoured aerosol is subjected to both flavouring and aerosolgeneration.

Viewed from another aspect, there can be provided a device configured toimpart flavouring to an airstream admitted the device prior to theairstream reaching an aerosol generator of the device, the devicethereby operable to deliver a flavoured aerosol from an outlet. Thus adevice can create a flavoured aerosol by passing a whole air volumethrough both flavouring and aerosol generation without contaminating aflavouring source with aerosol particles and/or condensate.

Viewed from a further aspect, there can be provided a method ofgenerating a flavoured aerosol, the method comprising: imparting flavourto an airflow by passing airflow through a flavour reservoir to causeflavour molecules and/or particles to be carried by the airflow;generating an aerosol by passing the airflow carrying flavour moleculesand/or particles through an aerosol generator that evaporates a liquidinto the airflow to create a flavoured aerosol; and delivering theflavoured aerosol to a mouthpiece. Thus a flavoured aerosol can begenerated in such manner as to avoid a flavouring reservoir becomingcontaminated with aerosol particles and/or condensation of liquid froman aerosol, while at the same time providing that the while air volumeof the flavoured aerosol is subjected to both flavouring and aerosolgeneration.

BRIEF DESCRIPTION OF THE FIGURES

The present disclosure will now be discussed, by way of example only,with reference to the following drawings in which like referencenumerals denote like elements.

FIG. 1 shows a cross-sectional side view of an aerosol delivery devicecomprising an aerosol-forming member according to a first example;

FIG. 2 shows a cross-sectional side view of an aerosol delivery portionof the aerosol delivery device shown in FIG. 1 ;

FIGS. 3 to 7 show example aerosol forming members;

FIG. 8 shows an example aerosol-forming member located in an aerosolchamber;

FIGS. 9 a and 9 b show example control circuits; and

FIG. 10 shows cross-sectional side view of an aerosol delivery devicecomprising an aerosol-forming member according to another example.

While the presently described approach is susceptible to variousmodifications and alternative forms, specific embodiments are shown byway of example in the drawings and are herein described in detail. Itshould be understood, however, that drawings and detailed descriptionthereto are not intended to limit the scope to the particular formdisclosed, but on the contrary, the scope is to cover all modifications,equivalents and alternatives falling within the spirit and scope asdefined by the appended claims

DESCRIPTION

Referring to FIG. 1 , there is shown a first example of an aerosoldelivery device. The aerosol delivery device 1 comprises an aerosoldelivery portion 1′ and a power portion 1″. In the present example, theaerosol delivery portion 1′ and power portion 1″ are arranged asseparate regions of a single, unitary, aerosol delivery device 1 havinga single housing 2 that houses both portions. In other examples, theaerosol delivery portion 1′ and power portion 1″ can be removablyconnected to enable a given power portion 1″ to receive a number ofdifferent aerosol delivery portions 1′ and/or to enable a given aerosoldelivery portion 1′ to receive a number of different power portions 1″.In such alternative examples, the housing 2 may be openable to enablereplacement of one portion or may be divided in correspondence to thedivision of the portions such that each portion includes its ownrespective housing part.

The aerosol delivery device 1 may be configured to be re-usable ordisposable. In the example in which the aerosol delivery portion 1′ andpower portion 1″ are separable, either or both of the aerosol deliveryportion 1′ and power portion 1″ may be configured as being re-usable ordisposable.

The power portion 1″ provides a source of electrical power for poweringone or more components within the aerosol delivery portion 1′. In thepresent example, the power portion 1″ has with the housing a battery 30.Delivery of power from the battery 30 to the aerosol delivery portion 1′is controlled by electric circuitry 34. In other examples the batterymay be replaced by another portable power source such as a capacitivepower store such as a supercapacitor or ultracapacitor, a mechanicalpower source such as a spring or dynamo, or an alternative chemicalenergy source such as a fuel cell.

FIG. 2 shows the aerosol delivery portion 1′ in greater detail. As canbe seen from FIG. 2 , the aerosol delivery portion 1′ is containedwithin housing 2 and has a mouthpiece 3 at one end and an attachmentelement at the other end. The attachment element is configured toconnect (either permanently or releasably) to the power portion 1″. Asshown in FIG. 2 , the attachment element has a connection member 35 toprovide for electrical connection between the power portion 1″ and anypower utilising elements of the aerosol delivery portion 1′.

The aerosol delivery portion 1′ as shown in FIG. 2 defines a gas pathwaytherethrough, the gas pathway having an inlet 5, a flavouring reservoir36, a plenum chamber 4, an aerosol chamber 6 (also referred to astubular channel 18), refining member 32 and an outlet aperture 7 thatextends through the mouthpiece 3. Air can be encouraged to flow throughthe gas pathway by the application of suction at the mouthpiece 3. Suchsuction may typically be provided by a user drawing air through theaerosol delivery device 1 when inhaling to receive a delivery ofaerosol. In overview, air taken in through the inlet 5 and passing alongthe gas pathway first picks up flavouring material from the favouringreservoir 36 before the forming of an aerosol at the aerosol chamber 6for delivery to the outlet aperture 7. This process will be described inmore detail below.

As shown in FIG. 2 , the flavouring reservoir 36 provides an inletpassage or channel between the inlet aperture 5 and the plenum chamber4. In some examples a single inlet 5 may be provided and in otherexamples a number of inlets 5 may be provided at different points aroundthe circumference of the housing 2. The inlet passage or channelprovided by the flavouring reservoir has an annular cross section andencompasses the aerosol chamber 6 and associated aerosol forming member10. In the configuration of the present example, the air inside theinlet passage and the aerosol inside the tubular channel 18 (aerosolchamber 6) are flowing in opposite directions.

As fresh air moves through the inlet passage it passes over or throughthe flavouring reservoir 36 which results in the release of flavours.The flavours disperse in the air and are taken downstream together withthe air. The flavour enriched/flavoured air is then collected in theplenum chamber 4. The plenum chamber 4 acts to provide uniformity to theflow of air to the aerosol chamber 6/tubular channel 18. The air entersthe aerosol chamber 6 via an air inlet 31′.

As will be described in more detail below, the aerosol forming member 10has a chamber wall 25 surrounding the aerosol chamber 6, then a liquidreservoir matrix 26 is arranged outside the chamber wall, with theaerosol chamber 6 having an aerosol chamber inlet 31′ and an aerosolchamber outlet 31″. Separation between the inlet passage/flavouringreservoir 36 and the liquid reservoir matrix 26 is provided by a supportmember 37 located between the liquid reservoir matrix 26 and theflavouring reservoir 36. The aerosol forming member 10 uses heatprovided by the flow of electrical current to aid the aerosolgeneration.

In the present example, the flavouring reservoir 36 is located aroundthe aerosol forming member 10. While the heat generated by the heatingelement of the aerosol forming member 10 is primarily used to vaporiseliquid provided from the liquid reservoir matrix 26, a portion of thatheat may be used to heat up the flavouring reservoir 36 to an elevatedtemperature. This secondary or waste heat can be transferred to theflavouring reservoir by thermal conduction through components of theaerosol forming member 10 and support member 37. For example, heat maybe conducted through the chamber wall 25, through the liquid reservoirmatrix 26 and through the tubular support member 37 holding the aerosolforming member 10 and the liquid reservoir matrix 26, and therebyprovided to the flavouring reservoir 36 and the flavours containedtherein.

This conductive heat transfer enables the flavouring reservoir 36 toreach temperatures that it would not reach otherwise, enabling enhancedrelease of flavours inside the reservoir. As the release of flavoursinside the reservoir is principally by diffusion, and as diffusion issignificantly temperature dependent in operation, the amount oftemperature elevation achieved in the flavouring reservoir by theconductive heat transfer need not be large to achieve the enhancedrelease of flavours. In addition to the thermal conductivity propertiesof the conductive heat transfer path and a heated structure of thereservoir, the amount of temperature rise may depend upon a number offactors associated with use of the device. For example the length of agiven draw or puff through the device may affect the operating time ofthe heating element and thus the total amount of heat generation thatoccurs during the draw or puff. Also, the time space between draws orpuffs may impact the total temperature rise if that timespan issufficiently short that at least some components of the device do notcool fully between draws or puffs. In practice a temperature rise on therange of 5° C. to 30° C. is anticipated to be feasible and a rise of aslittle of 1° C. is expected to provide some enhancement to the releaseof flavours. For a given implementation of the device, an expectedtemperature rise can be calculated and measured and in some examples itmay be appropriate to tailor the flavours in the flavouring reservoir tothe expected temperature rise.

The arrangement of the present example provides that the only gas toenter the flavouring reservoir is air introduced into the device via theinlet aperture(s) 5. Since the flavouring reservoir 36 does not receivevapour or aerosol generated inside the aerosol chamber 6, the surface offlavour providing elements within the flavouring reservoir will notattract or become clogged with condensate or aerosol particles generatedat the aerosol chamber 6.

As will be appreciated, the entire air volume drawn in by a user wheninhaling to receive a delivery of aerosol (which volume may typically beof the order of 30-80 ml) is provided to the aerosol chamber 6 and cancompletely be used for generating the aerosol. This can provide forefficient aerosol formation.

The flavouring reservoir 36 may comprise a permeable highly porouswadding or filling material. In the present example, the materialcompletely fills/extends over the channel cross section of the inletpassage or channel in which the flavouring reservoir 36 is arranged. Inother examples, the flavouring reservoir 36 may extend over a portionthat is less than the whole cross section. The flavouring reservoir 36may consist of a prefabricated pack or cartridge. In some examples, theflavouring reservoir may comprise or consist of tobacco or tobaccoextract. Suitable tobaccos are, in particular, dried fermented tobacco,reconstituted tobacco, expanded tobacco or mixtures of the same. Thetobacco may be present as cut tobacco, such as fine cut tobacco, or asfine granulates or tobacco flour. Such forms provide a relatively largesurface area to facilitate the release of flavours contained in thetobacco. In another example, the flavouring reservoir 36 may comprise aninert wadding or filling material or another open-pored inert substrate,the surface of which is coated with a flavouring material. The coatingmay, for example, contain an extract, condensate or distillate oftobacco or tobacco smoke, or a fraction such as a volatile, aromatic orflavourful fraction of the aforementioned extracts, condensates ordistillates, or tobacco flour. Any material, such as the examples givenabove, of a flavouring extracted from or based upon, at least in part,tobacco may be termed a tobacco derivative. The coating canalternatively or additionally contain menthol or an essential oil.

The flavouring substance or material can be a substance insoluble inwater and/or glycerol. In the present context, insolubility isindicative of a solubility of less than one percent by weight at 20° C.and 1 atm. Thus, by providing for dispersal of flavourings into theairflow within the flavouring reservoirs, even flavourings that are notwater or glycerol soluble can be effectively included in the aerosolprovided by the aerosol delivery device.

Thereby a flavouring can be provided to the air entering through theinlet 5. As described above, the release of flavour to the passing aircan be facilitated or assisted by heating of the flavouring reservoir,for example using the approach of conducting excess heat from theaerosol forming device 10 to the flavouring reservoir 36.

In the present example, the flavouring reservoir 36 is additionallyconfigured as a flow resistor 33. The flow resistor 33 provides the mainpressure drop when a user is drawing in air (inhaling through thedevice, also referred to as drawing on the device or puffing on thedevice). The arrangement of the flow resistor can be configured toprovide a level of pressure drop appropriate to a particular intendeduse. In one example, the pressure drop can be configured to correspondto or approximate the pressure drop that would be expected of aconventional (i.e. ignited tobacco type) cigarette. The comparativelylarge volume of the flavour reservoir 36 can provide flowcharacteristics that substantially correspond to those of a cigarette.In other examples where the device is configured for delivery offlavouring and/or liquid suspension in aerosol of materials other thanthose associated with tobacco smoking, an alternative pressure drop maybe configured as required for the intended use. The flow characteristicsof the arrangement depicted in FIG. 2 are substantially linear, i.e. thepressure drop over the flavouring reservoir 36 is directly proportionalto the flow rate through the flavouring reservoir 36.

FIG. 3 now shows more detail of the aerosol forming member. As shown inFIG. 3 , an aerosol-forming member 10 a comprises a material that isconfigured to wick and heat a solution such that the sheet of materialcan absorb solution and thereafter heat it up such that it evaporatesand forms a vapour. The material used in the present examples issheet-like in nature and comprises two major opposing surfaces 20, 21.The sheet of material may comprise an open-pored structure, foamstructure or interconnecting network of pores, all of which form acapillary structure. The capillary structure enables the aerosol-formingmember 10 a to wick or absorb a solution. The term “capillary structure”used herein is to be understood as a structure through which liquid or asolution can travel as a result of capillary action.

The aerosol-forming member 10 a of the present example may be made of aporous, granular, fibrous or flocculent sintered metal(s) so as to forma capillary structure. For instance, Bekipor™ sintered fibre materialfrom Bekaert (www.bekaert.com) falls in this category of materials. Inother examples, the aerosol-forming member 10 a comprises an open-poredmetallic foam or a group of layers of wire mesh or calendered wire meshwhich also form capillary structures. The aerosol-forming member 10 amay be formed from stainless steel. Furthermore, the aerosol formingmember 10 a may be formed with a capillary structure that extendsthroughout the whole aerosol-forming member 10 a such that it is exposedon the two major surfaces 20, 21 of the sheet of material. In someexamples, one of the major surfaces 20, 21 may be sealed with a metallicfoil or cover that is sintered or attached to said major surface.Alternatively, a region of one or both of the major surfaces 20, 21 maybe sealed. In another example, the aerosol-forming member 10 a isconfigured such that the capillary structure does not extend throughoutthe whole aerosol-forming member. In another example, a thin supportlayer may be sintered onto one or both of the major surfaces 20, 21.Such a support layer may be formed from a wire mesh made of stainlesssteel.

The material from which the aerosol-forming member 10 a is formed isheatable in that it comprises sufficient electrical resistivity so thatwhen current is passed through, the aerosol-forming member 10 a heats upto a temperature sufficient to cause the solution held in the capillarystructure to evaporate or vaporise. Therefore, in the present examples,the aerosol-forming member 10 a can be considered to comprise a heatingelement formed with a capillary structure such that the heating elementand the capillary structure are integrated and form a single entity orunit.

In the above described examples wherein the sheet of material comprisesa single layer configured to wick and heat a solution, the sheet ofmaterial can be described as comprising a heating element and a wickthat are arranged in the same surface.

Additionally, the aerosol-forming member 10 a may comprise anycombination of the aforementioned structures and materials, e.g. byproviding multiple layers of different structures/materials, the layersbeing joined together, e.g. by sintering.

In one such example, the aerosol-forming member comprises a sheet ofmaterial that is sheet-like in nature and formed from a plurality oflayers. For example, the aerosol-forming member 10 a may comprise afirst heatable layer acting as a heating element. This first layer isformed from a material that is configured to be heated up. This firstlayer may be formed from a metal, such as stainless steel. Theaerosol-forming member 10 a may further comprise a second layer formedwith an open-pored structure, foam structure or interconnecting networkof pores, all of which form a capillary structure. The capillarystructure enables the aerosol-forming member 10 a to wick or absorb asolution. This second layer may be made of a porous, granular, fibrousor flocculent material so as to form the capillary structure.Alternatively, the second layer may comprise an open-pored foam, fabricor a group of mesh layers forming the capillary structure. The secondlayer may be made of a non-conductive material such as glass, carbon orceramic. This second layer acts as a wick. The first layer (heatingelement) and the second layer (wick formed with a capillary structure)are laid on top of each other so as to form a sheet of material havingtwo opposing major surfaces, wherein the capillary structure may beexposed on one or both of the major surfaces. In this example, the sheetof material can be described as comprising a heating element and a wickarranged in parallel surfaces. In one example, the first layer may beformed of a metal wire mesh or metal foil and the second layer may beformed of a glass fibre structure or fabric fritted onto or otherwiseattached to the first layer.

In another example, the first layer also comprises a capillary structureas described above with reference to the second layer, such that thefirst layer can both heat and wick a solution. In this example, thesheet of material can be described as comprising a heating element and awick that are arranged in the same surface and in parallel surfaces.

In another example, the sheet of material comprises a third layer thatis similar to the second layer in that it comprises a capillarystructure. The second and the third layer sandwich the first layer suchthat the capillary structure is exposed on both major surfaces of thesheet of material.

The sheet of material according to any of the above described exampleshas a thickness or depth that typically falls within the range of 20-500μm. In some examples, the thickness falls within the range of 50 to 200μm. The thickness or depth should be understood as meaning the distancebetween the two major surfaces 20, 21 of the sheet of material.

FIGS. 3 and 4 show the aerosol-forming member 10 a in an unfolded stateor position and FIG. 6 shows the aerosol-forming member 10 a in a foldedstate or position. The sheet of material has a first or central section11 and a second and a third section 12, 13 on either side of the centralsection 11. The dashed lines in FIG. 3 represent the boundaries betweenthe sections 11, 12, 13. The second 12 and third 13 sections are formedwith slots or notches 14 that extend from opposing long edges 12 a, 13 aof the aerosol-forming member 10 a towards and into the first section11. In the arrangement shown in FIG. 3 , the second section 12 is formedwith five slots 14 and the third section 13 is formed with four slots14, although other configurations of numbers of slots are possible. Theslots 14 as illustrated in FIG. 3 are approximately parallel to oneanother and spaced apart across the second and third sections 12, 13.

Opposing free ends of the first section 11 act as electrical terminals15, 16. The electrical terminals 15, 16 are configured to beelectrically connected, e.g. via an electric circuitry 34, to a powersource, such as the battery 30, so that an electric current can bepassed across the aerosol-forming member 10 a. The electrical terminals15, 16 may extend from the first section as seen in FIG. 2 enabling themto slot into connection holes (not shown) of the aerosol deliverydevice, the connection holes being electrically connected to the powersource. Alternatively, an electrically conductive wire connected to thepower source may be clipped, soldered or welded onto each electricalterminals 15, 16 so that a current can be passed across theaerosol-forming member 10 a. In some examples, the electrical terminalsare in line with adjacent edges of the second and third sections 12, 13such that the terminals do not protrude. These terminals may beconnected to an electrically conductive wire via a clip and/or the wiremay be soldered or welded onto the terminals. It should also beunderstood that the electrical terminals may be of any other shape andit is envisaged that other means suitable for connecting the electricalterminals to the power source may be used.

When a current is passed through the aerosol-forming member 10 a, theslots 14 compress the electric field 17 such that it is substantiallycontained within the first section 11 as illustrated in FIG. 4 . Thedashed lines in FIG. 4 represent boundaries between the first, secondand third sections 11, 12, 13. As a result, the first section 11 isprimarily or directly heated up whilst the second and third sections 12,13 remain relatively unheated, although some heat generated by thecurrent passing through the first section is expected to cause someheating of the second and third sections 12, 13. Heat that is generatedin or which is conducted to the second and third sections can then beonwardly conducted to provide a small level of heating to the flavouringreservoir 36 as described above. Additionally or alternatively heat maybe transferred to the flavour reservoir by one or more of radiation heatoriginating from the heated first section 11 and absorbed by the chamberwall, and condensation heat released from vapour condensing on chamberwall 25. The heat transferred to the flavouring reservoir can be thoughtof as secondary heat or waste heat as such heat is not directly used forgenerating the aerosol.

The present teachings are however not limited to an aerosol-formingmember 10 a comprising slots so as to contain the heat within the firstsection 11. An example of such an arrangement is shown in FIG. 5 , wherethe sheet of material comprises discrete sections with differentmaterial properties. The first section 11 is made of a material of lowelectrical resistivity whereas the second or the third sections 12, 13are formed from a material with high electrical resistivity such thatwhen a potential difference is applied between the terminals 15, 16, ancurrent will primarily pass through the first section. It should beunderstood that the first section may also be formed with a capillarystructure such that it extends throughout the whole aerosol-formingmember. The difference in electrical resistivity results in that thefirst section 11 heats up relatively to the second and third sections12, 13.

An example of such an embodiment is wherein the sheet of materialcomprises a non-conductive fibre web or fabric made of glass or carbonfibres, glass or carbon fibre yarns or any other non-conductive andinert fibre materials. The fibre web or fabric provides the capillarystructure and extends throughout all sections of the sheet of material.Conductive fibres or wires are incorporated in the fibre web or fabricin a first or central section of the sheet of material making said firstor central section heatable. The conductive fibres or wires may be madeof stainless steel or of a heating wire alloy like Chromium Nickel.Alternatively, conductive fibres may replace non-conductive fibres andconductive wires (heating wires) may replace non-conductive yarns.

Thus it will be understood that a variety of constructions consistentwith the present teachings are possible to achieve primary heating of afirst section 11 to facilitate aerosol generation and to achievesecondary heating by way of conduction of heat from the aerosol formingmember to the flavour reservoir.

Referring now to FIG. 6 , there is shown the aerosol-forming member 10 ain a folded state or position. The second and third sections 12, 13 arefolded about the first section 11 such that the second and thirdsections 12, 13 enclose the first section 11 and form a channel 18.Regions 19 a, 19 b of the second and third sections 12, 13 overlap suchthat the channel 18 is completely enclosed in a direction about thefirst section 11. The first section 11 is substantially planar or flatand suspended in the channel 18 such that it extends across the channel18.

It should be understood that the second and third sections 12, 13 do nothave to form a tubular channel 18. In alternative examples the secondand third sections 12, 13 are folded about the first section 11 suchthat they form a channel having an oval, square, rectangular or anyother type of polygonal cross-section.

It should also be appreciated that the first section 11 is not limitedto being planar or flat. In an alternative example, the first section 11comprises corrugations having ridges and grooves such that it follows ameandering or oscillating path, or a sinusoidal curve. The ridges andgrooves may extend in a direction parallel to the opposing long edges 12a, 13 a of the sheet of material.

In another example, as shown in FIG. 7 , the third section 13 is omittedsuch that the aerosol-forming member 10 c has a first section 11 and asecond section 12. The second section 12 extends from the first section11 and folds about the first section 11 such that the second section 12forms a channel 18 and the first section 11 is suspended across thechannel 18. Alternatively, the second section 12 partially encloses thefirst section 11. For example, the second section 12 may extend around asingle surface of the first section such that the cross-section of theaerosol-forming member has a semi-circular shape.

Referring now to FIG. 8 , the aerosol-forming member 10 a is located inthe aerosol chamber 6. The aerosol forming member thus defines thechamber wall 25 adjacent or proximal a liquid reservoir matrix. Thechamber wall therefore may be expected to be at a boundary edge of thestructure making up the reservoir matrix. The liquid reservoir matrix 26comprises a capillary structure, for example an interconnecting porousor open-porous structure, such that it can hold a solution or liquid.The liquid reservoir matrix 26 may be formed from a fibre material, forexample polyethylene or polyester fibres. In an example where heat is tobe provided to the flavouring reservoir 35 by conduction of secondaryheat from the aerosol forming member, the liquid reservoir may beconfigured to provide conduction of the secondary heat. This may beprovided by the reservoir matrix itself being thermally conductive ormay be provided by thermally conductive elements passing through oraround the reservoir matrix.

The shape of the aerosol chamber 6 defined by the chamber wall 25corresponds to the shape of the aerosol-forming member 10 a. In thearrangement shown in FIG. 8 , the second and third sections 12, 13contact the liquid reservoir matrix 26. In other examples, it may bethat only one of the second and third sections 12, 13 contacts theliquid reservoir matrix 26. Alternatively, if the aerosol-forming memberonly comprises a second section 12 as seen in FIG. 7 then only thesecond section is in contact with the liquid reservoir matrix 26. Itshould also be understood that it is not necessary for the whole secondand/or third sections 12, 13 to contact the liquid reservoir matrix 26.For example, only a portion of the second and/or third sections maycontact the liquid reservoir matrix 26. In such examples it may be thecase that surface sections of the liquid reservoir matrix 26 (not incontact with sections 12, 13) effectively form sections of the chamberwall 25. In another example the aerosol-forming member 10 a may contactthe liquid reservoir matrix 26 only via the outer edges of sections 12,13. In this example the chamber wall is completely formed by the liquidreservoir matrix 26.

As will be appreciated, the aerosol forming chamber and aerosol formingmember may be constructed in any appropriate manner that provides foraerosol formation as air passes through a chamber. Thus as analternative, so-called atomisers based upon use of a heating coil woundaround a fibre wick may be used.

As is illustrated in FIG. 8 , the first section 11 is located across theaerosol chamber 6.

Advantageously, the liquid reservoir matrix 26 does not have to be madeout of a heat resistant material as it is shielded from the heat of thefirst section 11 by the second and/or third sections 12, 13 that are notsubstantially heated up during operation of the aerosol delivery device1. The secondary heat conducted through or across the reservoir matrixis of sufficiently small magnitude that special thermal resistance isnot expected to be required,

The liquid reservoir matrix 26 holds a solution that is formed intoaerosol by the aerosol-forming member 10 a. The solution is drawn orabsorbed into the aerosol-forming member 10 a by capillary action viathe capillary structure of the second and the third sections 12, 13. Thesolution is spread throughout the capillary structure of theaerosol-forming member 10 a, i.e. the first, second and third sections11, 12,13. When the first section 11 is heated up, the solutionevaporates from the first section 11 so as to form a vapour which uponcondensation forms an inhalable aerosol. Thereafter, and even during theheating, the first section 11 is replenished with solution by capillaryaction moving solution from the liquid reservoir matrix 26, via thesecond and third sections 12, 13 to the first section 11. This isdescribed in more detail below.

The capillarity of the aerosol-forming member 10 a may be greater thanthe capillarity of the liquid reservoir matrix 26 so as to induce flowof solution from the liquid reservoir matrix 26 towards theaerosol-forming member 10 a. The capillarity is defined by the pore sizeand the wetting conditions of the respective capillary structures.

As previously described, the power source enabling the aerosol-formingmember 10 a to heat up may be a battery 30. The battery 30 is controlledby the electric circuitry 34 which include a controller and may bemounted on a printed circuit board (PCB). Examples of illustrativecircuit structures are shown in FIGS. 9 a and 9 b.

As is shown in FIG. 9 a , the electrical terminals 15, 16 of theaerosol-forming member 10 a are electrically connected to the positiveand negative terminals of the battery 30 respectively as previouslydescribed. Control of electrical current to the terminals 15, 16 isprovided by the electrical circuit 34. The circuit of this exampleincludes a pressure-activated switch 40 that activates responsive to asignal from a pressure sensor 41. The pressure sensor 41 is arranged todetect a pressure alteration when a user commences inhaling through theaerosol delivery device. The pressure sensor may for example be arrangedin fluid communication with the plenum chamber 4 in order to detect thepressure change. Although it is indicated in FIG. 9 that the pressuresensor 41 is connected to the electric circuit 34 via the connectionmember 35, it is also possible to arrange the pressure sensor 41 at theelectric circuit 34 and to provide fluid communication between theplenum chamber 4 and the pressure sensor 41 via a passage extendingthrough the connection member 35. The signal from the pressure sensor 41then activates the switch 40 (either directly or via a controller) so asto allow a flow of current from the battery 30 to the terminals 15, 16.The switch 40 may be an electrical switch such as a power-MOSFETswitching circuit activatable responsive to the signal from the pressuresensor. The switch and any control circuitry therefor may be provided ata PCB of the electric circuit 34.

As shown in the example of FIG. 9 b , the control of the supply ofcurrent from the battery to the terminals 15, 16 may be controlled via aswitch 42 that activates responsive to a user-activated switch 43. Theuser-activated switch may be located at an accessible position on orrecessed into the housing 2. The switch 42 may be activated based upon adirect connection to the user-activated switch 43. Alternatively, acontrol circuit may be provided to control the switch 42 responsive toactivation of the user-activated switch 43. The switch 42 may be anelectrical switch such as a power-MOSFET switching circuit activatableresponsive to the signal from the user-activatable switch 43. The switchand any control circuitry therefor may be provided at a PCB of theelectric circuit 34.

In addition, the switching circuit may additionally provide automaticcontrol of the temperature, for example, by using temperature sensors toenable the supply of current to be stopped once a threshold temperatureis reached. The switching circuit may additionally or alternativelyprovide automatic control of duration, to enable the supply of currentto be stopped once a threshold activation time is reached.

In some examples, the circuit 34 may be configured to very low or zeropower requirements other than when the switch is activated to indicatethat provision of current to the terminals 15, 16 is required.

When current is drawn from the battery 30 and through the sheet ofmaterial, the electrical resistance of the sheet of material causes thefirst section 11 of the sheet of material to increase in temperature. Inthe embodiment wherein the sheet of material comprises several layers,the resistance of the conductive layer acting as a heating elementcauses the first section 11 to increase in temperature, which in turnheats up the adjacent non-conductive second and/or third layers of thefirst section 11.

Operation of the aerosol delivery device 1 will now be described withreference to FIGS. 1 and 8 . In use, the user may manually activate theaerosol delivery device 1 (for example see the arrangement of FIG. 9 b )or the aerosol delivery device 1 may be activated automatically (forexample see FIG. 9 a ) as the user starts to inhale through the aerosoldelivery device 1. In either approach, the battery 30 provides apotential difference between the electrical terminals 15, 16 of theaerosol-forming member 10 a as the aerosol delivery device is activated,causing current to flow between the electrical terminals 15, 16 suchthat the first section 11 of the sheet of material increases intemperature. The heat is substantially contained within the firstsection 11 due to the slots 14, although it should be appreciated thatthe heat may be contained within the first section by other means asdescribed above. It will also be appreciated that secondary heat may beconveyed to the flavouring reservoir 35 as described above. Thisincrease in temperature at the first section 11 causes the solution heldin the capillary structure of the first section 11 of the sheet ofmaterial to evaporate so as to form a vapour. The vapour mixes with airdrawn into the aerosol delivery device 1 via inlet 5, flavouringreservoir 35, plenum chamber 4 and chamber inlet 31′ by suction causedby a user inhaling through the device. The vapour mixes with air in theaerosol chamber 6, and as this occurs the vapour condenses and formsdroplets such that an inhalable aerosol is produced.

The aerosol-forming member 10 a according to any of the above describedembodiments is located in the housing such that the planes of the majorsurfaces 20, 21 are parallel to or substantially aligned with thedirection of the airflow through the aerosol chamber 6. Thus, when asolution is held in the aerosol-forming member 10 a and it is heated upsuch that the solution evaporates, the solution evaporates in adirection transverse to the direction of the airflow. In the embodimentswherein the capillary structure is exposed on both sides of the sheet ofmaterial, the solution is evaporated from both sides in oppositedirections as indicated by the arrows in FIG. 8 . The vapour mixes withair so as to form aerosol in the channel 18 formed by the second and/orthird sections 12, 13. The channel 18 directs the flow of aerosolthrough the aerosol delivery device towards the user.

When the aerosol forming device is activated, it is likely that excessvapour will form and then condense onto the chamber wall 6 formed by thesecond and/or third sections 12, 13 of the aerosol-forming member 10 a.The condensation heat released may thus provide a source of heat fortransfer to the flavour reservoir; the condensate will be reabsorbedinto the capillary structure of sections 12, 13 and resupplied tosection 11 of the aerosol-forming member 10 a by capillary action asdiscussed above. In addition to any such condensation heat, the supplyof secondary or waste heat to the flavour reservoir may also be providedby conductive heat transferred within the aerosol forming member fromthe high temperature section 11 to the adjacent cooler sections 12, 13.Further, the supply of secondary or waste heat to the flavour reservoirmay also be provided by radiation heat transferred from the hightemperature section 11 to the adjacent cooler sections 12, 13. Heat rayscan cross the aerosol chamber 6 and are then absorbed on the chamberwall 25 formed by sections 12, 13. All three sources of heat togetherare expected to be active to some extent, with the relative ratiotherebetween being dependent upon the exact device configuration.Together these mechanisms provide the secondary or waste heat. Thiswaste heat is passed through or around the liquid reservoir matrix 36 soas to reach the flavouring reservoir 36 for heating the flavouringcontained therein.

After the aerosol-forming member 10 a has been activated and aerosol hasformed in the channel 18, the aerosol is drawn through the channel 18 asthe user continues to inhale. The aerosol then exits the aerosol chamber6 through a chamber outlet 31″ as seen in FIG. 2 . The aerosol thenpasses through an optional aerosol refining member 32 provided in thehousing 2, causing the aerosol to be cooled. The refining member 32 mayalso contain further flavouring agents such as menthol that are releasedinto the flow of aerosol before entering the user's mouth via the outletaperture 7 provided in the mouthpiece 3. Meanwhile, the solution thathas evaporated from the capillary structure of the first section 11 ofthe sheet of material is replaced by fresh solution from the liquidreservoir matrix 26 due to the capillary effect of the capillarystructure as described above and the second and/or third section beingin contact with the liquid reservoir matrix 26. Fresh air enters thechannel 18 via the inlet aperture 5, flavouring reservoir 36, plenumchamber 4 and chamber inlet 31′. In some examples, a pressure dropelement or flow resistor 33 is provided so that the flow of air into theaerosol chamber 6 can be controlled. The flow resistor 33 may consist ofa simple aperture or hole and may be identical with the inlet aperture 5in the housing 2. Alternatively the flow resistor 33 may consist of aporous body similar to a cigarette filter providing the flow resistanceof a conventional cigarette. In some examples the flow resistor 33 maybe provided by the material as discussed above that provides a structurefor holding or providing the flavouring within the flavouring reservoir.In such examples this material thus provides dual functionality offlavour carrying and flow restriction.

Thus there have now been described examples of implementing theoperation and structure of an aerosol delivery device that utilisessecondary heat from an aerosol generation structure to warm a flavouringsource to facilitate distribution of flavouring from the flavouringsource to incoming air before that incoming air reaches the aerosolgeneration structure.

FIG. 10 illustrates another example of an aerosol delivery device. Theaerosol delivery device 1 comprises an aerosol delivery portion 1′ and apower portion 1″. In the present example, the aerosol delivery portion1′ and power portion 1″ are arranged as separate regions of a single,unitary, aerosol delivery device 1 having a single housing 2 that housesboth portions. In other examples, the aerosol delivery portion 1′ andpower portion 1″ can be removably connected to enable a given powerportion 1″ to receive a number of different aerosol delivery portions 1′and/or to enable a given aerosol delivery portion 1′ to receive a numberof different power portions 1″. In such alternative examples, thehousing 2 may be openable to enable replacement of one portion orcomponent (such as a power source 30) or may be divided incorrespondence to the division of the portions such that each portionincludes its own respective housing part.

The aerosol delivery device 1 may be configured to be re-usable ordisposable. In the example in which the aerosol delivery portion 1′ andpower portion 1″ are separable or openable, either or both of theaerosol delivery portion 1′ and power portion 1″ may be configured asbeing re-usable or disposable.

In this example, the portably power source 30 (which may be a battery orother portably power source as discussed with reference to FIG. 1 above)does not use the full diameter of the housing 2, but rather has locatedthereabout (either wholly surrounding or adjacent in part) the gaspathway from the inlet 5 to the plenum chamber 4. As in the previousexamples, this gas pathway has arranged therein a flavouring reservoir36. The flavouring reservoir 36 operates in the same manner as thatdiscussed with reference to FIGS. 1 and 2 above, save in thearrangements for warming of the flavouring reservoir 36.

As in the example described above, as fresh air moves through the inletpassage it passes over or through the flavouring reservoir 36 whichresults in the release of flavours. The flavours disperse in the air andare taken downstream together with the air. The flavourenriched/flavoured air is then collected in the plenum chamber 4. Theplenum chamber 4 acts to provide uniformity to the flow of air to theaerosol chamber 6/tubular channel 18. In the configuration of thepresent example, the air inside the inlet passage and the aerosol insidethe tubular channel 18 (aerosol chamber 6) are flowing in likedirections but are separated by axial offset between the centre of flowthrough the inlet passage and tubular channel and by the plenum chamber4.

In the example of FIG. 10 , two options for transfer of heat to theflavouring reservoir 36 can be employed, either independently or incombination.

In the first of these options, the property of many batteries toexperience a slight temperature increase when supplying current isutilised. Thus, when the portable power supply is a battery or otherpower supply that tends to experience a temperature increase whensupplying current, the heat generated by the power supply 30 may be usedto provide the supply of heat to the flavouring reservoir 36 arrangesabout or adjacent the power supply 30.

The second of these options utilises a separate heat generation thatprovides heat for the flavouring reservoir 36 other than by way ofconducting secondary heat from the aerosol forming member 10. Suchseparate heat generation could be provided by providing for the controlcircuit 34 to allow a low of current through one or more conductivestructures in or adjacent to the flavouring reservoir 36 at the sametime as the provision of current to the aerosol forming member 10.

As in the example described above, this conductive heat transfer enablesthe flavouring reservoir 36 to reach temperatures that it would notreach otherwise, enabling enhanced release of flavours inside thereservoir.

Thus there have now been described examples of implementing theoperation and structure of an aerosol delivery device that utilisessecondary heat from an aerosol generation structure or an alternativeheat source to warm a flavouring source to facilitate distribution offlavouring from the flavouring source to incoming air before thatincoming air reaches the aerosol generation structure. It will be seenthat the examples presented provide a compact structure.

It will be appreciated that implementations may also be provided inwhich no addition heat provision is made to the flavouring source andinstead the incoming air is passed through the flavouring reservoirwithout heating of the flavouring reservoir before the air reaches theaerosol generation structure.

The above described embodiments of the aerosol-forming member 10 of theaerosol delivery device 1 are described for use with a solution. Itshould be understood that this solution may comprise certainconstituents or substances that may have a stimulatory effect on theuser. These constituents or substances may be of any kind that issuitable for being delivered via inhalation. The solution in which theconstituents or substances are held or dissolved may primarily consistof water, ethanol, glycerol, propylene glycol or mixtures of theaforementioned solvents. By means of a sufficiently high degree ofdilution in an easily volatile solvent, such as ethanol and/or water,even substances which are otherwise difficult to evaporate can evaporatein a substantially residue-free manner, and thermal decomposition of theliquid material can be avoided or significantly reduced.

It should be understood that the term “channel” used herein is notlimited to a specific cross-section. Furthermore, the channel may becompletely enclosed about the longitudinal axis of the channel, howeverit should also be appreciated that the channel may not be enclosed butopen along a section parallel to the longitudinal axis of the channel.

It is also envisaged that the aerosol-forming member 10 according to anyof the embodiments described above may be oxidised or coated with anon-conductive material so as to prevent a short circuit.

This disclosure shows by way of illustration various embodiments inwhich the present teachings may be practiced and provide for anaerosol-forming member, aerosol delivery device component and aerosoldelivery device. The advantages and features of the disclosure are of arepresentative sample of embodiments only, and are not exhaustive and/orexclusive. They are presented only to assist in understanding and teachthe claimed features. It is to be understood that advantages,embodiments, examples, functions, features, structures, and/or otheraspects of the disclosure are not to be considered limitations on thedisclosure as defined by the claims or limitations on equivalents to theclaims, and that other embodiments may be utilised and modifications maybe made without departing from the scope and/or spirit of thedisclosure. Various embodiments may suitably comprise, consist of, orconsist in essence of, various combinations of the disclosed elements,components, features, parts, steps, means, etc. In addition, thedisclosure includes other teachings not presently claimed, but which maybe claimed in future.

1. An aerosol delivery device comprising: an air inlet; an aerosolchamber arranged to provide an aerosol in air passing therethrough; aplenum chamber downstream of the air inlet and upstream of the aerosolchamber; and an aerosol outlet; wherein the air inlet, aerosol chamberand aerosol outlet are arranged in fluid communication in that order. 2.The aerosol delivery device of claim 1, wherein the aerosol deliverydevice is configured to cause an airstream to flow in a first directionwhile passing through the plenum chamber and to flow in a seconddirection while passing through the aerosol chamber, wherein the seconddirection is substantially perpendicular to the first direction.
 3. Theaerosol delivery device of claim 1, further comprising an inlet passage,between the air inlet and the aerosol chamber, for delivering air fromthe air inlet to the aerosol chamber, wherein the air inlet passage isoffset from the aerosol chamber.
 4. The aerosol delivery device of claim1, wherein the aerosol delivery device further comprises a pressuresensor for detecting a pressure change when a user commences inhalingthrough the aerosol delivery device, wherein the pressure sensor isarranged in fluid communication with the plenum chamber in order todetect the pressure change.
 5. The aerosol delivery device of claim 4,wherein the aerosol delivery device further comprises a passage toprovide fluid communication between the plenum chamber and the pressuresensor, wherein the passage extends from the plenum chamber in adirection away from the air inlet.
 6. The aerosol delivery device ofclaim 1, further comprising an electric terminal for supplying power toan aerosol forming member from the aerosol delivery device, wherein theair from the air inlet is configured to pass the electric terminalbefore reaching the aerosol chamber.
 7. The aerosol delivery device ofclaim 6, wherein the electric terminal is located next to the plenumchamber.
 8. The aerosol delivery device of claim 1, wherein the aerosolchamber is parallel to the inlet passage.
 9. The aerosol delivery deviceof claim 1, wherein the air inlet comprises a plurality of air inlets.10. The aerosol delivery device of claim 9, wherein the aerosol chamberis located between the plurality of air inlets.
 11. The aerosol deliverydevice of claim 9, wherein the plurality of air inlets surround theaerosol chamber.
 12. The aerosol delivery device of claim 1, wherein theaerosol delivery device comprises a mouthpiece comprising a mouthpieceoutlet, wherein the aerosol outlet is in fluid communication with themouthpiece outlet arranged to deliver an aerosol therethrough whensuction is applied to the mouthpiece.
 13. The aerosol delivery device ofclaim 1, further comprising a housing, wherein the air inlet extendsthrough the housing.
 14. The aerosol delivery device of claim 13,wherein the plenum chamber is located between the housing and theaerosol chamber.
 15. The aerosol delivery device of claim 13, whereinthe plenum chamber is at least partially defined by the housing.
 16. Theaerosol delivery device of claim 13, wherein the aerosol delivery devicecomprises an aerosol delivery portion and a power portion which isconfigured to be removably connected to the aerosol delivery portion,wherein the aerosol delivery portion comprises the aerosol chamber andthe aerosol outlet.
 17. A method of generating a flavored aerosol,comprising: imparting an airflow through an air inlet to a plenumchamber; detecting a pressure change caused by the airflow using apressure sensor which is in fluid communication with the plenum chambervia a passage between the plenum chamber and the pressure sensor,wherein the passage extends from the plenum chamber in a direction awayfrom the air inlet; delivering the airflow from the plenum chamber intoan aerosol chamber for generating a flavored aerosol; and delivering theflavored aerosol to a mouthpiece.
 18. The method of claim 17, furthercomprising triggering heating of at least one aerosol generatorresponsive to detection of the airflow.
 19. The method of claim 17,wherein the airflow flows in a first direction while passing through theplenum chamber, and flows in a second direction while passing into theaerosol chamber, wherein the second direction is substantiallyperpendicular to the first direction.
 20. A method of directing the flowof air through an aerosol delivery device, the method comprising:delivering an airflow from at least one air inlet of the aerosoldelivery device into a plenum chamber of the aerosol delivery device;delivering the airflow from the plenum chamber into an aerosol chamberfor generating a flavored aerosol; and delivering the flavored aerosolto a mouthpiece outlet of the aerosol provision device.